Since its introduction in 2010, shredlage, a new concept in processing corn silage, has captured the imagination and support of a significant proportion of dairy producers and the dairy feeding industry The generalized concept of shredlage is to produce a corn silage with longer particle length, yet as good or better grain processing, than has been achievable with the so-called current kernel processors, and thereby improve the performance of dairy cattle fed high levels of this forage. Though initial research results show promise, there are indications that if the processing does not achieve the required results, undesirable outcomes, such as suboptimal ensiling and sorting, may occur.

AdvancingCorn Silage Processing Technology
For a number of years there has been a movement towards feeding increasing levels of corn silage to dairy cows as an idealized combination of forage (stalk and leaf) and grain and cost effective source of energy. This movement has been associated with changes in varieties, as well as later harvest, intended to increase the starch content of the silage. This, in turn, necessitated the development of kernel processing technology to ensure optimal starch utilization and minimize fecal losses.
Initially, kernel processing corn silage harvested at a traditional 3/8 to 1/2 inch theoretical length of cut (TLOC) caused reductions in chewing and milk fat content that were corrected by increasing the TLOC to 3/4 to one inch. As varieties have continued to change and there has been a tendency to harvest more mature, higher DM corn silages, there has continued to be a challenge to achieve a desirable balance between extent of kernel processing score and optimal physical fiber. It is apparently for this reason that concept of shredlage has become so popular within the dairy industry in such a short period of time.

Shredlage vs. Shredlage®
Citing Dr. Randy Shaver, Dairy Nutritionist at the University of Wisconsin, a recent article suggested as much as 10 percent of the U.S. dairy herd might currently be being fed some form of shredlage — as the concept and process is generically being referred to. (The word Shredlage® has been trade-marked by the originators and partners in the resulting company, Shredlage® LLC.)
The concept for shredlage is clearly demonstrated in the definition given on the Shredlage® website (www.shredlage
.com), as follows:
“In addition to crushing the kernel, Shredlage® is longer cut corn measuring 26mm—32mm TLC with the stalk ripped length wise into planks and strings allowing for improved effective fiber, better packing and a greater exposure to the inner cells of the plant.”
This definition should be kept in mind, especially in relation to the theoretical length of cut and description of the “shredded” forage particles when considering trying shredlage, as it is the type of material that was used in the only published research trial so far that has compared shredlage (i.e. Shredlage®) with conventional kernel processed silage.

University Of Wisconsin Shredlage Study
In the study conducted by Dr. Randy Shaver’s research group at the University of Wisconsin, dairy cows fed Shredlage® (SHRD: 30mm TLOC, 2.5mm roll gap) ate 1.4 lbs. more dry matter and gave 1.8 lbs. more milk per day, on an energy corrected basis, than those fed conventional kernel processed corn silage (CPCS: 19mm TLOC, 3mm gap). The shredlage material had a greater forage particle size (31.5% vs. 5.6% retained on a 19 mm sieve), as well as a greater kernel processing score (75% vs. 60.3%), which in the end appeared to be the primary reason for the production differences; fiber utilization and milk composition did not differ, and there was no evidence of sorting. The results of this study have been widely communicated and appear to have been highly influential in the current interest in, and support for, adoption of shredlage technology. However, field results may not necessarily be the same if the processing results are not the same.

Sub-Optimal Field Results
In the fall of 2013 I called on a dairy in northern Wisconsin on which we had previously identified and resolved a sorting problem, only to be informed they were concerned they were once again having problems with sorting. This was confirmed at the feed-bunk where there were large amounts of intact corn stalk pieces over two inches (50 mm) in length and greater than half inch in diameter, as well as an excessive amount of leaf material up to six inches in length.
The dairy producer explained they had decided to try shredlage that year given the positive discussion he had heard, and was now wondering if he might have made a mistake. At the silo, it was clear the crop had gone in fairly dry (about 40% DM), and that the TLOC had be set at over an inch and a half (40 mm), with most of the stalk material being longer than that, as well as cut on the bias, indicating that the material had gone through the cutter on an angle, as opposed to straight on. This, along with folding, seemed to explain the large amount of leaf material exceeding three inches (75 mm) in length. Furthermore, little of this material showed any signs of having been “shredded” and resembled the large “cigar butts” as described by Shredlage® LLC.
Interestingly, there was no evidence of intact corn cobs or unprocessed grain which is the goal of traditionally processed corn silage. These latter points were the justification used by the contractor to show he had done a good job putting up the silage, “and there was obviously a lot more effective fiber,” despite the evidence that the silage had not packed well, smelled as if it had not fermented well, or was spoiling easily, and was being readily sorted by the cattle. Clearly, this was not the shredlage that producers and nutritionists generally have in mind, and what we must avoid producing.

Effective Corn Silage Fiber?
A number of years ago Dr. Bill Mahanna, Dairy Nutritionist with Pioneer, talked about the need to focus on both the “Green and the Gold” when talking about corn silage, green being its forage component and gold being its grain component. I believe this concept is very useful and that it is further helpful to view corn silage blend of fair to medium quality grass silage and high moisture corn, rather than a single forage.
As such, the concept of shredlage has two simultaneous goals:
1) To increase the particle length, and thus the physical effectiveness, of the grass silage component to stimulate chewing, and especially rumination,
2) while maintaining or improving the particle size reduction of the grain component to maximize total starch digestion and minimize potential loss in the manure.
To a certain extent this is what appear to have been accomplished in the University of Wisconsin study, especially since there was no observable sorting with the longer shredlage.
Field research at Jaylor has given us confidence that problems with sorting and low butterfat are rare when more than 50% of the TMR (as-fed) is retained on the top two sieves (8 and 19 mm) of the Penn State Particle Separator combined, with a least some, but not more than 10%, being retained on the top sieve. At the same time, it is important that there is adequate surface moisture in the TMR (i.e. the TMR is not too dry) to prevent easy sifting and of the small, easily digested particles from the forage particles by the cattle during eating.
In the University of Wisconsin study the total amounts of material retained above the 8 mm sieve was 53.8% and 56.4% for the shredlage and conventionally processed TMRs, respectively. Both of these were above the 50% standard, so it may not be surprising that both rations had similar, and generally accepted levels of butterfat content (3.7%). And, though the shredlage TMR also had more material retained on a 19 mm sieve (15.6% vs 3.5%) than is normally recommended in North America, the characteristics of the shredded particles were apparently such that they resisted the sorting that often occurs with this proportion of long particles in other rations. The relatively high moisture content of the rations (45%-46% DM) in the study might have helped, along with the fact that both corn silages were put up at an ideal moisture level (65%).
These were certainly not the conditions and results that were obtained by the producer in northern Wisconsin. For optimal results, Shredlage® LLC, in a recent presentation in New York, recommended Shredlage® be put up 65% to 67% moisture, at a TLOC of 26 to 30 mm with roll spacing set to achieve a kernel processing score of 70%. As crop DM content and maturity increase, both TLOC and roll spacing need to decreased, and vice versa. BMR corn reportedly also requires a narrower setting. At a presentation in Southern Ontario Dr. Shaver reported that past research suggests conventionally processed corn silage is best harvested at a TLOC of 19 mm and a gap setting of 1 mm.
Research by Dr. Karen Beauchemin’s group at the Agriculture Research Centre, Lethbridge, Alberta, Cananda, has demonstrated that the amount of forage in the diet is about ten times more effective than forage length alone in stimulating chewing behavior and influencing rumen pH. More recent research involving a group from Italy clearly demonstrated that increasing the average length of a given forage beyond about one-half inch did not appreciably change the average length of particles entering the rumen due to compensation by chewing during eating. Type of forage and/or chemical and moisture content of the forage had a much larger effect on the size of particles entering the rumen than did length alone. This research strongly supports the concept that there may exist a threshold beyond which there is little benefit to increase particle size of forages fed to dairy cattle. This is especially so if it leads to sorting and its subsequent detrimental effects.

Where To From Here?
Further light on this subject may be shed by the results of a second study, currently being completed at University of Wisconsin, which will compare BMR shredlage against conventionally processed BMR corn silage and conventionally processed BMR corn silage plus hay. The bottom line is, however, whether putting up shredlage or conventional processed corn silage, it’s best to check moisture content, TLOC and processing results at time of harvest to be sure you are getting the optimal results you expect, and need; when you go to feed, it’s too late — “Because Nutrition Matters.”®

SIDEBAR: HOW IT ALL BEGAN
Jaylor founder, Jake Tamminga, was born and raised in Holland and immigrated with his family to Canada in 1977.
Growing up in a rural community, Tamminga was influenced by his early farming experiences. He was inspired to change the technical limitations he saw in the farming industry and began working in steel fabrication.
In 1993, Tamminga began designing and manufacturing innovative Vertical TMR (Total Mix Ration) feed mixers for dairy and beef farmers. The market response was tremendous to Tamminga’s final designs and mixers.
Jaylor was built upon word of mouth and success on farms. Its reputation for high quality spread rapidly, ensuring Jaylor mixers were soon distributed throughout North America and 42 countries world-wide.
Today, Jaylor is a successful international corporation, but has never forgotten where it started and still maintains its roots firmly planted on the farm, with its production facilities located in rural Orton, Ontario, Canada.
MISSION
Jaylor’s mission is to be the leading manufacturer of the highest quality vertical mixers that consistently maximize profitability by extracting the highest nutritional yield from the mix because nutrition matters.
VISION
Jaylor’s vision is to become a global nutritional leader in the agriculture and compost industries by offering premium quality and evolutionary innovative products supported by committed service.

BIO:
Dr. Alan Vaage is a Ruminant Nutritionist with over 30 years of experience in the dairy industry, specializing in rumen function and forage evaluation. He currently provides technical support for Jaylor Fabricating Inc., Orton, Ontario. Dr. Vaage can be contacted by email: nutrition@jaylor.com.